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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 95 (Engine Mechanical - 2.2L) >> Repair Instructions >> Off-Vehicle Repair Instructions >> Cylinder Head and Gasket Surface Cleaning and Inspection

Cylinder Head and Gasket Surface Cleaning and Inspection

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the spark plugs.
    Fig 1: Removing Spark Plugs
    G01580707Courtesy of GENERAL MOTORS CORP.
  2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, use the following faults to determine the cause.
    1. 2.1. Improper installation
    2. 2.2. Loose or warped cylinder head
    3. 2.3. Missing, off location or not fully seated dowel pins
    4. 2.4. Corrosion in the seal area around the coolant passages.
    5. 2.5. Chips or debris in the cylinder head bolt holes
    6. 2.6. Bolt holes in the cylinder block not drilled or tapped deep enough
    7. 2.7. Other
  3. Inspect the cylinder head gasket surface.
    • Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1).
    • Replace the cylinder head if the area between the valve seats is cracked (2).
    • Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).
  4. Clean the cylinder head bolts.

    Important:  Do not use a wire brush on any gasket sealing surface.

  5. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
  6. Clean the valve guides.
  7. Clean the threaded holes. Use a nylon bristle brush.
    Fig 2: Inspecting Cylinder Head Gasket Surface
    G01580708Courtesy of GENERAL MOTORS CORP.
  8. Clean the remains of the sealer from the plug holes.
  9. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.
  10. Replace all suspect bolts.
  11. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.

    Important:  Do not attempt to weld the cylinder head, replace it.

  12. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
  13. Inspect the cylinder head deck, the intake and exhaust manifold mating surfaces for flatness.
  14. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
  15. Inspect the sealing surfaces.
    Fig 3: Inspecting Cylinder Head Deck Surface For Flatness
    G01580709Courtesy of GENERAL MOTORS CORP.
  16. Inspect the cylinder head plugs.
    Fig 4: Inspecting Cylinder Head Plugs
    G01580710Courtesy of GENERAL MOTORS CORP.
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